user manual

The content in this manual has been carefully prepared and is believed to be accurate, but no
responsibility is assumed for inaccuracies.
User’s Manual
For
Leadshine reserves the right to make changes without further notice to any products herein to
improve reliability, function or design. Leadshine does not assume any liability arising out of the
DM442
application or use of any product or circuit described herein; neither does it convey any license
Fully Digital Stepping Drive
applications wherein a failure or malfunction of the product may directly threaten life or injury.
Version 1.0
©2010 All Rights Reserved
Attention: Please read this manual carefully before using the drive!
support or aircraft applications assumes all risks of such use and indemnifies Leadshine against all
under its patent rights of others.
Leadshine’s general policy does not recommend the use of its products in life support or aircraft
According to Leadshine’s terms and conditions of sales, the user of Leadshine’s products in life
damages.
©2010 by Leadshine Technology Company Limited.
All Rights Reserved
Contents
Table of Contents
1. Introduction, Features and Applications.................................................................... 1
Introduction ........................................................................................................... 1
Features ................................................................................................................. 1
Applications .......................................................................................................... 1
2. Specifications ............................................................................................................ 2
Electrical Specifications ........................................................................................ 2
Mechanical Specifications..................................................................................... 2
Elimination of Heat ............................................................................................... 2
Operating Environment and other Specifications.................................................. 3
3. Pin Assignment and Description ............................................................................... 3
Connector P1 Configurations ................................................................................ 3
Selecting Active Pulse Edge and Control Signal Mode ........................................ 4
Connector P2 Configurations ................................................................................ 4
4. Control Signal Connector (P1) Interface................................................................... 4
5. Connecting the Motor................................................................................................ 5
Connections to 4-lead Motors ............................................................................... 5
Connections to 6-lead Motors ............................................................................... 5
Half Coil Configurations ............................................................................... 5
Full Coil Configurations................................................................................ 6
Connections to 8-lead Motors ............................................................................... 6
Series Connections ........................................................................................ 6
Parallel Connections...................................................................................... 7
6. Power Supply Selection ............................................................................................ 7
Regulated or Unregulated Power Supply .............................................................. 7
Multiple Drives ..................................................................................................... 8
Selecting Supply Voltage....................................................................................... 8
7. Selecting Microstep Resolution and Drive Output Current....................................... 8
Microstep Resolution Selection ............................................................................ 8
Current Settings..................................................................................................... 9
I
Contents
Dynamic current setting .............................................................................. 10
Standstill current setting.............................................................................. 10
8. Wiring Notes ........................................................................................................... 10
9. Typical Connection.................................................................................................. 11
10. Sequence Chart of Control Signals ....................................................................... 11
11. Protection Functions.............................................................................................. 12
Over-current Protection............................................................................... 12
Over-voltage Protection .............................................................................. 12
Phase Error Protection................................................................................. 12
Protection Indications.................................................................................. 13
12. Frequently Asked Questions.................................................................................. 13
Problem Symptoms and Possible Causes ............................................................ 14
13. Professional Tuning Software ProTuner................................................................ 15
Introduction ......................................................................................................... 15
Software Installation ........................................................................................... 15
Connections and Testing ..................................................................................... 19
RS232 Interface Connection ............................................................................... 19
Testing the Stepping System ............................................................................... 19
Software Introduction.......................................................................................... 20
ProTuner Main Window .............................................................................. 20
ProTuner Toolbar......................................................................................... 20
Option.......................................................................................................... 21
Com Config Window .................................................................................. 21
Parameters Configuration Window ............................................................. 21
Tuning ......................................................................................................... 22
Anti-Resonance Introduction ...................................................................... 26
Internal Pluser( Pulse Generator) ................................................................ 27
Procedure for Achieving Optimum Performance ........................................ 28
Err_check .................................................................................................... 29
About........................................................................................................... 30
II
DM442 Digital Stepping Drive Manual V1.0
1. Introduction, Features and Applications
Introduction
The DM442 is a versatility fully digital stepping drive based on a DSP with advanced control
algorithm. The DM442 is the next generation of digital stepping motor controls. It brings a unique
level of system smoothness, providing optimum torque and nulls mid-range instability. Motor
self-test and parameter auto-setup technology offers optimum responses with different motors and
easy-to-use. The driven motors can run with much smaller noise, lower heating, smoother
movement than most of the drives in the markets. Its unique features make the DM442 an ideal
solution for applications that require low-speed smoothness.
Compared to the DM432C, DM442 can output more current. What’s more, owing to its higher
performance DSP, driven motors can achieve much higher speed (above 3000RPM) than that of
the DM432C, offering servo-like performances.
Features
l Anti-Resonance, provides optimum torque
l Supply voltage up to +40 VDC
and nulls mid-range instability
l Output current programmable, from 0.5A to
l Motor self-test and parameter auto-setup
4.2A
technology, offers optimum responses with
l Pulse input frequency up to 200 KHz
different motors
l TTL compatible and optically isolated input
l Multi-Stepping allows a low resolution step
l Automatic idle-current reduction
input to produce a higher microstep output
(Reduction rate can be software configured)
for smooth system performance
l Support PUL/DIR and CW/CCW modes
l Microstep resolutions programmable, from
l Over-voltage,
full-step to 102,400 steps/rev
over-current,
phase-error
protections
Applications
Suitable for a wide range of stepping motors, from NEMA frame size 17 to 34. It can be used in
various kinds of machines, such as laser cutters, laser markers, high precision X-Y tables, labeling
machines, and so on. Its unique features make the DM442 an ideal solution for applications that
require both low-speed smoothness and high speed performances.
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DM442 Digital Stepping Drive Manual V1.0
2. Specifications
DM442 Digital Stepping Drive Manual V1.0
Operating Environment and other Specifications
Electrical Specifications (Tj = 25℃/77℉)
Cooling
Natural Cooling or Forced cooling
Avoid dust, oil fog and corrosive gases
Environment
Parameters
Min
Typical
Max
Unit
Output current
0.5
-
4.2 (3.0 RMS)
A
Supply voltage
+20
+36
+40
VDC
Logic signal current
7
10
16
mA
Pulse input frequency
0
-
200
kHz
Isolation resistance
500
MΩ
Mechanical Specifications (unit: mm [inch])
Ambient Temperature
0℃ - 50℃ (32℉ - 122℉)
Humidity
40%RH - 90%RH
Operating Temperature
70℃ (158℉) Max
Operating Environment
Vibration
5.9m/s2 Max
Storage Temperature
-20℃ - 65℃ (-4℉ - 149℉)
Weight
Approx. 200g (7.05oz)
3. Pin Assignment and Description
The DM442 has two connectors, connector P1 for control signals connections, and connector P2 for
power and motor connections. The following tables are brief descriptions of the two connectors.
More detailed descriptions of the pins and related issues are presented in section 4, 5, 9.
Connector P1 Configurations
Pin Function
PUL+
PUL-
Figure 1: Mechanical specifications
DIR+
Elimination of Heat
l
l
l
Drive’s reliable working temperature should be <70℃(158℉), and motor working temperature
should be <80℃(176℉);
It is recommended to use automatic idle-current mode, namely current automatically reduce to
60% when motor stops, so as to reduce drive heating and motor heating;
It is recommended to mount the drive vertically to maximize heat sink area. Use forced cooling
method to cool the system if necessary.
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DIRENA+
ENA-
Details
Pulse signal: In single pulse (pulse/direction) mode, this input represents pulse
signal, each rising or falling edge active (software configurable); 4-5V when
PUL-HIGH, 0-0.5V when PUL-LOW. In double pulse mode (pulse/pulse) ,
this input represents clockwise (CW) pulse,active both at high level and low
level (software configurable). For reliable response, pulse width should be
longer than 2.5μs. Series connect resistors for current-limiting when +12V or
+24V used. The same as DIR and ENA signals.
DIR signal: In single-pulse mode, this signal has low/high voltage levels,
representing two directions of motor rotation; in double-pulse mode (software
configurable), this signal is counter-clock (CCW) pulse,active both at high
level and low level (software configurable). For reliable motion response, DIR
signal should be ahead of PUL signal by 5μs at least. 4-5V when DIR-HIGH,
0-0.5V when DIR-LOW. Please note that rotation direction is also related to
motor-drive wiring match. Exchanging the connection of two wires for a coil
to the drive will reverse motion direction.
Enable signal: This signal is used for enabling/disabling the drive. High level
(NPN control signal, PNP and Differential control signals are on the contrary,
namely Low level for enabling.) for enabling the drive and low level for
disabling the drive. Usually left UNCONNECTED (ENABLED).
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DM442 Digital Stepping Drive Manual V1.0
DM442 Digital Stepping Drive Manual V1.0
Selecting Active Pulse Edge and Control Signal Mode
The DM442 supports PUL/DIR and CW/CCW modes and pulse actives at rising or falling edge. See
more information about these settings in Section 13. Default setting is PUL/DIR mode and rising
edge active (NPN, and PNP control signal is on the contrary).
Connector P2 Configurations
Pin Function
Details
+Vdc
Power supply, 20~40 VDC, Including voltage fluctuation and EMF voltage.
GND
Power Ground.
A+, A-
Motor Phase A
B+, B-
Motor Phase B
Figure 3: Connection to PNP signal (common-cathode)
5. Connecting the Motor
The DM442 can drive any 2-phase and 4-phase hybrid stepping motors.
4. Control Signal Connector (P1) Interface
The DM442 can accept differential and single-ended inputs (including open-collector and PNP
output). The DM442 has 3 optically isolated logic inputs which are located on connector P1 to accept
line drive control signals. These inputs are isolated to minimize or eliminate electrical noises coupled
Connections to 4-lead Motors
4 lead motors are the least flexible but easiest to wire. Speed and torque will depend on winding
inductance. In setting the drive output current, multiply the specified phase current by 1.4 to
determine the peak output current.
onto the drive control signals. Recommend use line drive control signals to increase noise immunity
of the drive in interference environments. In the following figures, connections to open-collector and
PNP signals are illustrated.
Figure 4: 4-lead Motor Connections
Connections to 6-lead Motors
Like 8 lead stepping motors, 6 lead motors have two configurations available for high speed or high
torque operation. The higher speed configuration, or half coil, is so described because it uses one half
of the motor’s inductor windings. The higher torque configuration, or full coil, uses the full windings
of the phases.
Figure 2: Connections to open-collector signal (common-anode)
Half Coil Configurations
As previously stated, the half coil configuration uses 50% of the motor phase windings. This gives
lower inductance, hence, lower torque output. Like the parallel connection of 8 lead motor, the torque
output will be more stable at higher speeds. This configuration is also referred to as half chopper. In
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DM442 Digital Stepping Drive Manual V1.0
setting the drive output current multiply the specified per phase (or unipolar) current rating by 1.4 to
determine the peak output current.
DM442 Digital Stepping Drive Manual V1.0
Parallel Connections
An 8 lead motor in a parallel configuration offers a more stable, but lower torque at lower speeds. But
because of the lower inductance, there will be higher torque at higher speeds. Multiply the per phase
(or unipolar) current rating by 1.96, or the bipolar current rating by 1.4, to determine the peak output
current.
Figure 5: 6-lead motor half coil (higher speed) connections
Full Coil Configurations
The full coil configuration on a six lead motor should be used in applications where higher torque at
lower speeds is desired. This configuration is also referred to as full copper. In full coil mode, the
motors should be run at only 70% of their rated current to prevent over heating.
Figure 8: 8-lead motor parallel connections
NEVER disconnect or connect the motor while the power source is energized.
6. Power Supply Selection
Figure 6: 6-lead motor full coil (higher torque) connections
Connections to 8-lead Motors
8 lead motors offer a high degree of flexibility to the system designer in that they may be connected
in series or parallel, thus satisfying a wide range of applications.
Series Connections
A series motor configuration would typically be used in applications where a higher torque at lower
speeds is required. Because this configuration has the most inductance, the performance will start to
degrade at higher speeds. In series mode, the motors should also be run at only 70% of their rated
current to prevent over heating.
Figure 7: 8-lead motor series connections
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The DM442 can match medium and small size stepping motors (from NEMA frame size 14 to 34)
made by Leadshine or other motor manufactures around the world. To achieve good driving
performances, it is important to select supply voltage and output current properly. Generally speaking,
supply voltage determines the high speed performance of the motor, while output current determines
the output torque of the driven motor (particularly at lower speed). Higher supply voltage will allow
higher motor speed to be achieved, at the price of more noise and heating. If the motion speed
requirement is low, it’s better to use lower supply voltage to decrease noise, heating and improve
reliability.
Regulated or Unregulated Power Supply
Both regulated and unregulated power supplies can be used to supply the drive. However,
unregulated power supplies are preferred due to their ability to withstand current surge. If regulated
power supplies (such as most switching supplies.) are indeed used, it is important to have large
current output rating to avoid problems like current clamp, for example using 4A supply for 3A
motor-drive operation. On the other hand, if unregulated supply is used, one may use a power supply
of lower current rating than that of motor (typically 50%~70% of motor current). The reason is that
the drive draws current from the power supply capacitor of the unregulated supply only during the
ON duration of the PWM cycle, but not during the OFF duration. Therefore, the average current
withdrawn from power supply is considerably less than motor current. For example, two 3A motors
can be well supplied by one power supply of 4A rating.
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DM442 Digital Stepping Drive Manual V1.0
Multiple Drives
DM442 Digital Stepping Drive Manual V1.0
Microstep
Steps/rev.(for 1.8°motor)
SW5
SW6
SW7
SW8
1 to 512
Default/Software configured
ON
ON
ON
ON
2
400
OFF
ON
ON
ON
4
800
ON
OFF
ON
ON
8
1600
OFF
OFF
ON
ON
16
3200
ON
ON
OFF
ON
32
6400
OFF
ON
OFF
ON
64
12800
ON
OFF
OFF
ON
128
25600
OFF
OFF
OFF
ON
5
1000
ON
ON
ON
OFF
only sufficiently high supply voltage for intended applications, and it is suggested to use power
10
2000
OFF
ON
ON
OFF
supplies with theoretical output voltage of +20 ~ +36VDC, leaving room for power fluctuation and
20
4000
ON
OFF
ON
OFF
back-EMF.
25
5000
OFF
OFF
ON
OFF
7. Selecting Microstep Resolution and Drive Output Current
40
8000
ON
ON
OFF
OFF
50
10000
OFF
ON
OFF
OFF
100
20000
ON
OFF
OFF
OFF
125
25000
OFF
OFF
OFF
OFF
It is recommended to have multiple drives to share one power supply to reduce cost, if the supply has
enough capacity. To avoid cross interference, DO NOT daisy-chain the power supply input pins of
the drives. Instead, please connect them to power supply separately.
Selecting Supply Voltage
The power MOSFETS inside the DM442 can actually operate within +20 ~ +40VDC, including
power input fluctuation and back EMF voltage generated by motor coils during motor shaft
deceleration. Higher supply voltage can increase motor torque at higher speeds, thus helpful for
avoiding losing steps. However, higher voltage may cause bigger motor vibration at lower speed, and
it may also cause over-voltage protection or even drive damage. Therefore, it is suggested to choose
Microstep resolutions and output current are programmable, the former can be set from full-step to
102,400 steps/rev and the latter can be set from 0.5A to 4.2A. See more information about Microstep
and Output Current Setting in Section 13.
However, when it’s not in software configured mode, this drive uses an 8-bit DIP switch to set
microstep resolution, and motor operating current, as shown below:
Current Settings
For a given motor, higher drive current will make the motor to output more torque, but at the same
time causes more heating in the motor and drive. Therefore, output current is generally set to be such
that the motor will not overheat for long time operation. Since parallel and serial connections of
motor coils will significantly change resulting inductance and resistance, it is therefore important to
set drive output current depending on motor phase current, motor leads and connection methods.
Phase current rating supplied by motor manufacturer is important in selecting drive current, however
the selection also depends on leads and connections.
Microstep Resolution Selection
When it’s not in software configured mode, the first three bits (SW1, 2, 3) of the DIP switch are used
When it’s not in software configured mode, microstep resolution is set by SW5, 6, 7, 8 of the DIP
to set the dynamic current. Select a setting closest to your motor’s required current.
switch as shown in the following table:
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DM442 Digital Stepping Drive Manual V1.0
Dynamic current setting
Peak Current
RMS Current
SW1
SW2
SW3
Default/Software configured (0.5 to 4.2A)
ON
ON
ON
1.46A
1.04A
OFF
ON
ON
1.91A
1.36A
ON
OFF
ON
2.37A
1.69A
OFF
OFF
ON
2.84A
2.03A
ON
ON
OFF
3.31A
2.36A
OFF
ON
OFF
3.76A
2.69A
ON
OFF
OFF
4.20A
3.00A
OFF
OFF
OFF
DM442 Digital Stepping Drive Manual V1.0
high current flowing through motor coils (even when motor is at standstill). Pulling or plugging
connector P2 with power on will cause extremely high back-EMF voltage surge, which may
damage the drive.
9. Typical Connection
A complete stepping system should include stepping motor, stepping drive, power supply and
controller (pulse generator). A typical connection is shown as figure 9.
Notes: Due to motor inductance, the actual current in the coil may be smaller than the dynamic
current setting, particularly under high speed condition.
Standstill current setting
SW4 is used for this purpose. OFF meaning that the standstill current is software configured, and ON
meaning that standstill current is set to be the same as the selected dynamic current.
By default, the current automatically reduced to 60% of the selected dynamic current two second
after the last pulse. Theoretically, this will reduce motor heating to 36% (due to P=I2*R) of the
original value. Reduction rate and idle time can be configured in the PC software ProTuner. See
more information in section 13.
10. Sequence Chart of Control Signals
In order to avoid some fault operations and deviations, PUL, DIR and ENA should abide by some
rules, shown as following diagram:
8. Wiring Notes
l
In order to improve anti-interference performance of the drive, it is recommended to use twisted
pair shield cable.
l
To prevent noise incurred in PUL/DIR signal, pulse/direction signal wires and motor wires
should not be tied up together. It is better to separate them by at least 10 cm, otherwise the
disturbing signals generated by motor will easily disturb pulse direction signals, causing motor
position error, system instability and other failures.
l
If a power supply serves several drives, separately connecting the drives is recommended
instead of daisy-chaining.
l
It is prohibited to pull and plug connector P2 while the drive is powered ON, because there is
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Figure 9: Typical connection
10
Figure 10: Sequence chart of control signals
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DM442 Digital Stepping Drive Manual V1.0
Remark:
a)
DM442 Digital Stepping Drive Manual V1.0
Protection Indications
t1: ENA must be ahead of DIR by at least 5µs. Usually, ENA+ and ENA- are NC (not
connected). See “Connector P1 Configurations” for more information.
b)
t2: DIR must be ahead of PUL active edge by 5µs to ensure correct direction;
c)
t3: Pulse width not less than 2.5µs;
d)
t4: Low level width not less than 2.5µs.
11. Protection Functions
To improve reliability, the drive incorporates some built-in protection functions. The DM442 uses
one RED LED to indicate what protection has been activated. The periodic time of RED is 5 s
(seconds), and how many times the RED turns on indicates what protection has been activated.
Because only one protection can be displayed by RED LED, so the drive will decide what error to
display according to their priorities. See the following Protection Indications table for displaying
priorities.
Priority
Time(s) of ON
Sequence wave of RED LED
1st
1
Over-current protection
2nd
2
Over-voltage protection
3rd
4
Phase error protection
12. Frequently Asked Questions
In the event that your drive doesn’t operate properly, the first step is to identify whether the problem
is electrical or mechanical in nature. The next step is to isolate the system component that is causing
the problem. As part of this process you may have to disconnect the individual components that make
up your system and verify that they operate independently. It is important to document each step in
Over-current Protection
the troubleshooting process. You may need this documentation to refer back to at a later date, and
Over-current protection will be activated when continuous current exceeds the limit or in case of
short circuit between motor coils or between motor coil and ground, and RED LED will turn on once
within each periodic time (5 s).
Over-voltage Protection
these details will greatly assist our Technical Support staff in determining the problem should you
need assistance.
Many of the problems that affect motion control systems can be traced to electrical noise, controller
software errors, or mistake in wiring.
When power supply voltage exceeds 50±1 VDC, protection will be activated and RED LED will
turn on twice within each periodic time (5 s).
Phase Error Protection
Motor power lines wrong & not connected will activate this protection. RED LED will turn on four
times within each periodic time (5 s).
Attention: When above protections are active, the motor shaft will be free or the LED will blink.
Reset the drive by repowering it to make it function properly after removing above problems. Since
there is no protection against power leads (﹢,﹣) reversal, it is critical to make sure that power
supply leads correctly connected to drive. Otherwise, the drive will be damaged instantly.
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Description
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DM442 Digital Stepping Drive Manual V1.0
13. Professional Tuning Software ProTuner
Problem Symptoms and Possible Causes
Symptoms
Possible Problems
No power
Microstep resolution setting is wrong
Motor is not rotating
DIP switch current setting is wrong
Fault condition exists
The drive is disabled
Motor phases may be connected in reverse
Motor rotates in the wrong direction
The drive in fault
This section will provide an overview of connection and basic setup instructions for Leadshine’s
digital stepping drive DM442 using the ProTuner software. These instructions will walk you through
the following steps necessary to start up your drive and motor. This section is intended for setting up
the drive with the ProTuner.
Software Installation
The ProTuner is windows based setup software for tuning Leadshine’s digital stepper drive DM442.
Something wrong with motor coil
It can run in windows systems, including Win95/Win98/WindowsNT/ Windows 2000/Windows XP.
Control signal is interfered
Wrong motor connection
Something wrong with motor coil
Current setting is too small, losing steps
Current setting is too small
Motor is undersized for the application
Motor stalls during acceleration
Introduction
DIP switch current setting is wrong
Control signal is too weak
Erratic motor motion
DM442 Digital Stepping Drive Manual V1.0
And the selected PC should have 1 serial port at least for communicating with the drive.
Double click “ProTuner_DM442_V2.0.exe” to begin installing the ProTuner. See Figure 11. Click
Next to enter the “License Agreement” window. See Figure 12.
Note: The user can get it from either Leadshine CD or website. Please get the latest version
from http://www.leadshine.com.
Acceleration is set too high
Power supply voltage too low
Inadequate heat sinking / cooling
Excessive motor and drive heating
Automatic current reduction function not being utilized
Current is set too high
Figure 11: Begin to install the ProTuner
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DM442 Digital Stepping Drive Manual V1.0
DM442 Digital Stepping Drive Manual V1.0
Figure 14: Installation folder settings
Figure 12: License agreement
Choose “I agree to the terms of this license agreement” and click Next to continue installation. The
user can enter user’s information in the following window. See Figure 13. After entering the user’s
information, click Next to select installation folder, where you would like to install the ProTuner. See
Figure 14.
Figure 15: Shortcut folder setting
Set the “Shortcut Folder” in Figure 15 and continue to install the ProTuner by following Figure 16
and Figure 17. An Installation Successful window will appear if the ProTuner is installed
successfully. See Figure 18.
Figure 13: User’s information settings
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DM442 Digital Stepping Drive Manual V1.0
DM442 Digital Stepping Drive Manual V1.0
Figure 16: Installation information summarization
Figure 18: Finish installation
Connections and Testing
Connect the stepping system according to the contents in previous sections and connect the PC to the
drive as the following figure.
RS232 Interface Connection
DM442
Figure 17: Installing the ProTuner
Figure 19: RS232 interface connection
Testing the Stepping System
Turn on the power supply, the green (Power) LED will light. The DM442 has default parameters
stored in the drive. If the system has no hardware and wirings problem, the motor should be locked
and the drive should be ready.
If the red LED immediately turns on (flickers), then check power supply, the motor, motor wirings
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DM442 Digital Stepping Drive Manual V1.0
and try again. Open the tuning software ProTuner and check drive status by clicking Err_check. If
it’s Phase Error, check the motor, motor wirings and try again.
DM442 Digital Stepping Drive Manual V1.0
Option
The user can choose three drop-down menus by clicking “Option”, including Com Configuration,
If the RED LED is OFF and the motor is normal, then you can start to tune the servo with ProTuner.
However, we recommend you see the following contents before starting tuning.
Software Introduction
Parameters Configuration, and Exit.
l
Com Configuration: Configure Com communication interface.
l
Parameteres Configuration: Read/write parameters between the drive and the ProTuner, or
save configuration as a file and load configuration from a file.
ProTuner Main Window
l
Exit: Exit the ProTuner.
Com Config Window
Menu Bar
Figure 21: RS232 communication configuration window
Serial Port: Select the serial communication port to which the drive is connected. The factory default
Status Bar
setting is COM1.
Baud Rate: Select the communication baud rate. The factory default setting is 38400.
Figure 20: ProTuner
ProTuner Toolbar
Current Loop Tuning
Com Configuration
Click Open button to establish a connection with the specified settings. When connecting, you can
Product Information
Error Check
read stored parameter setting from the drive to the ProTuner, or write new parameter setting from the
ProTuner to the drive settings in the parameters configuration window.
Parameters Configuration Window
Recommend to always keep this window active. In this window, the user can read the parameter
Parameters Configuration
System Configure
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setting from the drive, or write parameters setting to the drive after finishing to configure all the
Contact Information
20
Exit
settings. In addition, the user can also save the configuration to a file for later use or load a
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DM442 Digital Stepping Drive Manual V1.0
configuration from a stored file. See figure 22.
DM442 Digital Stepping Drive Manual V1.0
large current error, causing poor performances in tracking current setting command in each step like
Read RAM: Read parameter settings from the drive’s RAM to the ProTuner.
Figure 23. Too large Proportional Gain values will cause oscillations and unstable systems.
Write RAM: Write parameter settings from the ProTuenr to the drive’s RAM.
Write EEprom: Write parameter settings from the ProTuenr to the drive’s EEprom.
Reset Drive: Reset all parameter to default value.
Load configurations from a file
Save configuration to a file
Close this window.
Figure 23: Current Tuning window
Ki: Integral Gain. Integral Gain helps the drive to overcome static current errors. A low or zero value
for the Integral Gain may have current errors at rest. Increasing the Integral Gain can reduce the error.
If the Integral Gain is too large, the systems may “hunt” (oscillate) about the desired position.
Start button: The user can start a Step Response test by clicking this button. Start/Restart a Step
Response test to get an optimum response like Figure 23, and remember to save the settings to the
drive by clicking Write EEprom in parameters configuration window when finish tuning .
Figure 22: Parameters configuration window
Auto button: Click this button to auto-configure Kp and Ki for the connected motor. It has the same
effect as changing SW4 two times in one second.
Tuning
The user can choose one or two drop-down menu(s) by clicking Tuning, including CurrentLoop and
SystemConfig.
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CurrentLoop: In Current Tuning window, the user can tune the Kp (Proportional Gain) and
Ki (Integral Gain) of drive’s current loop to optimize responses with different motors.
Start/Restart a Step Response test to get an optimum response.
Kp: Proportional Gain. Proportional Gain determines the response of the drive to current setting
command. Low Proportional Gain provides a stable system (doesn’t oscillate), has low stiffness, and
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DM442 Digital Stepping Drive Manual V1.0
DM442 Digital Stepping Drive Manual V1.0
Figure 24: Kp=356, Ki=15 (poor performances)
Notes:
However, if the user does not want to tune the current loop after changing a different stepping motor,
then Motor self-test and parameter auto-setup technology of the DM442 can replace manual tuning
the drive with ProTuner. Just changes SW4 two times in 1 second (without ProTuner), or click Auto
button, and then the drive will auto-identify the new motor and auto-configure related control
parameters for optimum responses. Recommend use this function after changing the driven motor.
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SystemConfig:
Figure 25: System Configure Window
In SystemConfig window, the user can configure Peak Current, Microstep, Elec Damp, Idle Current,
Idle Time, Command Type, Active Edge and eliminate motor resonance. A built-in pulse generator
can be used for test during tuning. See Picture 25.
PeakCur: Peak Current. The value is the peak current to the selected motor and can be set from 0.1
to 4.2 A. The user can set the peak current with ProTuner or DIP switches, see more information
about setting output current of the drive in section 5 “Connecting the Motor” and section 7
“Selecting Microstep Resolution and Drive Output Current”.
MicroStep: Microstep Resolution. The value is drive’s microstep resolution setting and can be set
from 1 to 512. The user can set the microstep with ProTuner or DIP switches, See more information
about setting output current of the drive in section 7 “Selecting Microstep Resolution and Drive
Output Current”.
ElecDamp: Electronic Damping Coefficient. The electronic damping restrain resonance of the
system and prevent amplitude of the oscillation from increasing to the extend that it makes the motor
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DM442 Digital Stepping Drive Manual V1.0
out of control. The optimal value depends on the system, and the default value is 3000.
Idle Current: Standstill Current when motor stop. When the motor stop time exceeds the Idle
Time, the motor coil current reduces to Idle Current (In percentage). The percentage is rated to the
Peak Current.
DM442 Digital Stepping Drive Manual V1.0
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anti-resonant loop in the drive. The anti-resonant feature is not designed to damp such a 4 order
system. If the application of anti-resonance results in degradation or instability, it should be disabled.
1st ResonanceArea: Parameters for 1st resonance area. It is usually between 0.6rps and 1.2rps.
Amp1 is Amplitude adjustment for 1st resonance area.
Phase1 is Phase adjustment for 1st resonance area. The user can enter a value directly in the text box
Idle Time: See Idle Current.
Pulse Filter Enable: Click the check box will turn on the internal pulse smoother or filter of DM442.
DirectionDef: Direction Definition. Relate the default running direction to a HIGH level input in
DIR or Low level input in DIR. This panel is used for PUL/DIR command type only. Please note that
the default direction is also related to motor coil connections.
CommandType: Command Type of control signal, including PUL/DIR and CW/CCW. Set this
or move the slider bar back and forth to get an optimum value.
2nd ResonanceArea: Parameters for 2nd resonance area. It is usually between 1.2rps and 2.4rps.
Default Amp2 and Phase2 values are zero.
3rd ResonanceArea: Parameters for 3rd resonance area. It is usually between 2.4rps and 4.8rps.
Default Amp3 and Phase3 values are 128.
parameter according to Command Type of motion controller.
Internal Pluser( Pulse Generator)
ActiveEdge: Active Edge. The user can set the triggered edge of pulse command signal in this panel.
The internal pulse generator offers a simple motion control for self-test and anti-resonance tuning. The
When the drive works in CW/CCW mode, no matter what level is at fixed level terminal, the drive can
user can adjust moving velocity, configure the direction and repeats of the motion.
works properly.
Bidirectional: Click the check box to make the motion be bidirectional. Otherwise the motor only run
Anti-Resonance Introduction
in one direction.
Step motors are highly resonant, which results in vibration and ringing. The ringing utilizes a large
Positive: It is used to change the initial direction for the motion.
fraction of the motor's available torque – thereby wasting performance. Furthermore, at mid-range
velocities, the resonance can become so severe that the motor looses synchronization and stalls. The
DM442 drive provides robust anti-resonance control to stop the vibrations and maintain equilibrium.
This feature requires that the drive be configured with respect to the total inertia in the system. If set
improperly, the effectiveness of the feature may be diminished.
The user can invoke or disable the feature by setting Amp and Phase values in SystemConfig
window. Amp and Phase values all zero is to disable the feature, otherwise is to invoke the feature. It
should be enabled unless the system configuration either does not need it or cannot tolerate it. A
Interval: Stop time before the next motion repeat. Unit: ms.
Repeats: Motion repeat times. If it is bidirectional, one repeat is moving forward then back.
Distance: Moving distance in one direction in revolution.
Start/Stop: Start/Stop the motion.
Note:
system with loose couplings or viscous loading generally does not need this feature. If a system has
When you adjust the velocity by moving the slider forth and back, the motor velocity would not
compliant (springy) coupling and is absent appreciably viscosity, it may not respond well to the active,
change immediately as you expected. That is because the drive only read the new speed when it
changes direction. Also be careful about the initial direction and moving distance if the motor is
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DM442 Digital Stepping Drive Manual V1.0
DM442 Digital Stepping Drive Manual V1.0
installed on a machine. It is recommended that set low speed and small distance if you are not sure
whether the direction and distance is correct or not.
Procedure for Achieving Optimum Performance
Step 1: Start the motion test by clicking Start/Stop button. Find a resonance speed by slightly moving
the slider bar of internal pulse generator back and forth. You can also use the arrow keys to adjust the
speed precisely.
Step 2: Run the motor at the resonance speed and verify the motor smoothness. You may find a better
smoothing value by slightly moving the slider bars of AMP(s) and Phase(s) back and forth.
It is very important to make the AMP(s) and Phase(s) adjustments at the proper test speeds with an
unloaded motor. Running at an incorrect test speed will not excite the motor at its peak resonance,
making it more difficult to find proper adjustment values. Optimum AMP(s) and Phase(s) values may
be a little different between running the tests with an unloaded motor and a load motor.
For example, we find a resonance speed at 0.98 rps. We begin to move the Amp1 slider forth and the
motor vibration and noise became lower and lower. Finally we find the move is the smoothest when
Amp 1 is 3300. The motor vibration and noise increase if Amp 1 exceeds 3300. Then we follow the
same procedure to search the best point for Phase 1. See Figure 26. Anti-resonance tuning is done.
Figure 26: 1st Anti -Resonance Tuning (Speed=0.98rps)
Please remember to click Write EEprom to write the final parameter settings to the drive when finish
tuning.
Err_check
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Error Check: This window shows both the present status of each error event and their history.
Current error event(s) can be reset by clicking Erase Current Err! button, and all error events
can be reset by clicking Erase All! button. List of the last ten drive faults. #0 being the most
recent, #9 is the oldest. See Figure 27.
Figure 27: Error check window
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DM442 Digital Stepping Drive Manual V1.0
OverCurrent: Over-current Protection. Protection will be activated when continuous current
exceeds 16A.
OverVoltage: Over-voltage Protection. When power supply voltage exceeds 42±1 VDC, protection
will be activated.
PhaseErr: Phase Error Protection. Motor power lines wrong & not connected will activate this
protection.
ErrCounter: Displays current error(s) and current error history.
Erase Current Err!: Erase Current Err button. The user can clear current error(s) by clicking this
button.
Erase All!: Erase All! button. The user can clear all error(s) including error history by clicking this
button.
About
The user can choose two drop-down menus by clicking “About”, including Product Information and
Contact Us.
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Product Information window: Shows some product information about ProTuner.
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Contact Us window: Shows some contact information about Leadshine.
Figure 28: Product information
Figure 29: Contact information
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